Container blank and container with denesting feature

A blank for being formed into a container. The blank has a marginal area that includes a plurality of score lines for facilitating forming of the blank into the container. The score lines are positioned to facilitate formation of denesting features of the container. A container formed from the blank has denesting features.

Skip to: Description  ·  Claims  ·  References Cited  · Patent History  ·  Patent History
Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/275,215, filed Aug. 26, 2009.

INCORPORATION BY REFERENCE

U.S. Provisional Patent Application No. 61/275,215, which was filed on Aug. 26, 2009, is hereby incorporated by reference for all purposes as if presented herein in its entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to containers, trays, constructs, and/or blanks having features to facilitate denesting of stacked containers.

SUMMARY OF THE DISCLOSURE

In one aspect, the disclosure is generally directed to a blank for being formed into a container. The blank has a marginal area that includes a plurality of score lines for facilitating forming of the blank into the container. The score lines are positioned to facilitate formation of denesting features of the container.

In another aspect, the disclosure is generally directed to a container formed from a blank. The container includes denesting features that are formed by a plurality of score lines in a marginal portion of the blank.

In another aspect, the disclosure is generally directed to a blank for forming a container. The blank comprises a central portion, an edge, and a marginal portion between the edge and the central portion. The blank comprises a radius extending from a center of the blank to the edge. The marginal portion comprising a plurality of score lines. Each score line being positioned at an angle relative to the radius of the blank.

In another aspect, the disclosure is generally directed to a container formed from the blank having the features noted in the preceding paragraph. The container comprises a bottom wall formed from the central portion, a side wall extending upwardly from the bottom wall and being formed from at least a portion of the marginal portion, and a flange extending laterally outward from the side wall and being formed from at least a portion of the marginal portion.

In another aspect, the disclosure is generally directed to a container having an interior surface forming an interior space of the container and an exterior surface. The container comprises a bottom wall, a side wall extending upwardly from the bottom wall, and a flange extending laterally outward from a top of the side wall. The container has overlapped portions in at least a portion of the side wall and the flange. The overlapped portions form a first plurality of protrusions on the interior surface and a second plurality of protrusions on the exterior surface.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 show various views of various features of a blank and/or container of one embodiment of the present disclosure.

FIGS. 5 and 6 show various views of various features of a container of a second embodiment of the present disclosure.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure relates generally to various aspects of containers, constructs, trays, materials, packages, elements, and articles, and methods of making such containers, constructs, trays, materials, packages, elements, and articles. Although several different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations thereof, and modifications of the various aspects, implementations, and embodiments are contemplated hereby. In one illustrated embodiment, the present disclosure relates to forming a container or tray for holding food items or various other articles. However, in other embodiments, the container or tray can be used to form other non-food articles or may be used for heating or cooking.

FIG. 1 is a plan view of a blank 3 used to form a container 5 (FIG. 2) of one embodiment of the disclosure. In the illustrated embodiment, the blank 3 is generally circular and is for being press formed into the container 5 that is a generally circular tray. It is understood that the blank 3 can be press-formed into the container 5 by conventional forming tools such as are disclosed in U.S. Patent Application Publication No. 2005/0109653, the entire contents of which are incorporated herein by reference for all purposes. Also, the blank 3 can be press-formed into the container by other forming tools, such as are disclosed in International Publication No. WO 2008/049048, the entire contents of which are incorporated by reference for all purposes, or any other suitable forming tool assembly. Also, the blank 3 and the container 5 could be shapes other than circular (e.g., oval, rectangular, irregular, etc) without departing from the scope of this disclosure. The blank 3 of the present disclosure has features that allow the blank to be made of thinner material (e.g., paperboard) than is conventionally used, while still comprising denesting features that allow stacked containers to be easily separated.

As shown in FIG. 1, the blank 3 has a central portion 7, a radial edge 9, and a marginal portion 11 between the radial edge and the central portion. The blank 3 includes a lateral axis L1 and a longitudinal axis L2 that is generally perpendicular to the lateral axis. In the illustrated embodiment, the blank 3 includes a radius R that extends from the center C of the blank to the radial edge 9.

In one embodiment, the marginal portion 11 of the blank 3 includes a plurality of score lines 15. The score lines 15 are positioned at an angle A relative to the radius R. As shown in FIG. 1, each of the respective plurality of score lines 15 are oblique relative to each other, but the score lines could be otherwise positioned. In one embodiment the score lines 15 each extend from a first end point 17 that is spaced radially inward from the radial edge 9 to a second end point 19 that is adjacent the central portion 7 of the blank 3. In the illustrated embodiments the first end points 17 of adjacent score line 15 are spaced apart a distance D1, and the second end points 19 of adjacent score lines are spaced apart a distance D2. The scores lines 15 each have a length L3 between the first end point 17 and the second end point.

In one embodiment, the blank 3 has a radius R of at least approximately 3 inches (76 mm), and in the illustrated embodiment, at least approximately 3⅜ inches (86 mm). In one embodiment, the score lines 15 have a length L3 of at least about ¾ inch (19 mm), and in the illustrated embodiment, at least about 1 inch (25 mm). In one embodiment, the distance D1 between the first end points 17 is at least approximately ¼ inch (6 mm), and in the illustrated embodiment at least about ½ inch (13 mm). In one embodiment, the distance D2 between the second end points 19 is at least approximately ⅛ inch (3 mm), and in the illustrated embodiment, is at least approximately ⅜ inch (9.5 mm). In one embodiment, the angle A is at least about 15 degrees, in the illustrated embodiment, the angle A is at least about 30 degrees, and in another embodiment, the angle A is at least about 60 degrees. In one embodiment, the blank 3 comprises 18 point paperboard having a thickness of approximately 0.018″ (0.46 mm), but the blank 3 could have a larger or smaller thickness or could comprise other materials. In one embodiment, the distance D1 is at least about 25% greater than the distance D2, and in the illustrated embodiment, is at least about 33% greater. In one embodiment, the length L3 is at least about 10% of the radius R, in another embodiment, the length L3 is at least about 25% of the radius R, and in the illustrated embodiment, the length L3 is at least about 30% of the radius R. All of the dimensional information presented herein is intended to be illustrative of certain aspects of the disclosure and is not intended to limit the scope of the disclosure, as various other embodiments of the disclosure could include dimensions that are greater than or less than the dimensions included herein.

As shown in FIGS. 2 and 3, the container 5 formed from the blank 3 includes a bottom wall 25, a side wall 27 extending upwardly from bottom wall, and a flange 29 extending outwardly from the top of the side wall. The container 5 has an interior surface 103 and an exterior surface 105. The bottom wall 25 and side wall 27 at least partially define an interior space 30 of the interior surface 103 of the container 5. As shown in FIGS. 3, 3A, and 4, when the blank 3 is formed into the container 5, the score lines 15 form overlapped portions or pleats 31. Some of the overlapped portions 31 are protrusions that protrude outwardly from the interior surface 103 and others of the overlapped portions 31 are protrusions that protrude outwardly from the exterior surface 105 of the container 5. As shown in FIGS. 3 and 4, the overlapped portions or protrusions 31a on the interior surface 103 extend upwardly from a top surface 107 of the flange 29 and the overlapped portions or protrusions 31b on the exterior surface 105 extend downwardly from a bottom surface 109 of the flange. In the illustrated embodiment, the overlapped portions 31 are in the flange 29 of the container and the side wall 27, and extend down the side wall to a location adjacent the bottom wall 25. The overlapped portions 31 or protrusions could be otherwise shaped, arranged, and/or configured without departing from the disclosure.

As best shown in FIGS. 3 and 4, the forming tool (not shown) that presses the blank 3 into the container forms a stacking lug 35 on the exterior surface 105 of the side wall 27. In the illustrated embodiment, the stacking lug 35 extends outwardly from the exterior surface 105 of the container 5 around the perimeter of the side wall 27. The stacking lugs 35 are adjacent two compressed portions 37, 39 of the exterior surface 105 of the container. At the compressed portions 37, 39, the overlapped portions 31 are compressed at two locations adjacent to the stacking lug 35 so that the exterior surface 105 is substantially smooth at the compressed portions. The stacking lug 35 is formed by the uncompressed portions of the overlapped portions 31 on the exterior surface 105 of the container that protrude laterally outward from the compressed portions 37, 39. The stacking lugs 35 and compressed portions 37, 39 of the exterior surface 105 form denesting features for separating stacked containers. The stacking lug 35 and the compressed portions 37, 39 could be otherwise shaped and located without departing from the disclosure.

As shown in FIGS. 4 and 5, the containers 5 can be stacked in a generally nested configuration with the sidewall 27 of a top container at least partially received in the interior space 30 of a lower container. The containers 5 include denesting features to facilitate denesting, or separation of a container from the stack or nested configuration, by a denesting apparatus, such as the type disclosed in the incorporated by reference U.S. Patent Application Publication No. 2005/0109653, or any other type of denesting apparatus. The denesting features of the containers 5 include the stacking lugs 35 that allow the flanges 29 of the containers to be spaced apart from each other when the containers are in a stacked configuration. The stacking lug 35, protruding from the exterior surface 105 of the side wall 27 of a respective upper container 5, contacts the interior surface 103 of the side wall of the lower container that is located below the respective upper container in the nested configuration. The contact of the stacking lug 35 of the upper container 5 with the interior surface 103 of the side wall 27 of the lower container prevents the upper container 5 from being fully inserted into the interior space of the lower container so that the bottom walls 25 of respective containers are spaced apart from each other in the axial direction of the nested containers. Also, the flanges 29 of the containers 5 are spaced apart from each other in the axial direction of the nested containers by a distance D3 (FIG. 4) to facilitate denesting of the containers by use of a denesting apparatus that has features that slide between the adjacent flanges to separate or denest a respective container from the stacked arrangement.

The containers 5 can include other denesting features, such as any of the denesting features disclosed in the incorporated by reference U.S. Patent Application Publication No. 2005/0109653, or any other feature.

The orientation of the score lines 15 of the blank 3 of the present disclosure allow the overlapped portions or pleats 31 to protrude outward from the exterior surface 105 of the container 5 a sufficient distance to create the stacking lugs 35 when the 3 blank comprises a material having a reduced thickness (18 pt or less). The angular placement of the score lines 15 allows more material to accumulate at the pleats 31 so that height of the stacking lugs 35 is maintained even with the use of paperboard having a reduced thickness. The thicker stacking lugs 35 will keep multiple containers 5 (FIG. 4) spaced apart an increased stacking distance D3 to improve denestability of the trays. Such an increase in the stacking distance D3 can be seen in containers 5 formed from blanks 3 having angled score lines 15 and reduced thickness and lower cost material.

FIGS. 5 and 6 show the container 5 that has been coated with an external layer to form substantially smooth interior and exterior surfaces 103, 105 of the container. As with the previous embodiment, the container of FIGS. 5 and 6 has a stacking lug 35 protruding from the compressed portions 37, 39 of the exterior surface 105 to provide the denesting features of the container.

In accordance with the above-described embodiments of the present disclosure, a score line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, score lines include: a fold line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.

The foregoing description illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and are within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the disclosure.

Claims

1. A blank for forming a container, the blank comprising:

a central portion;
an edge; and
a marginal portion between the edge and the central portion, the blank comprising a radius extending from a center of the blank to the edge, the marginal portion comprising a plurality of score lines, each score line being positioned to intersect the radius and being positioned at an angle relative to the radius of the blank that intersects the score line, each of the score lines comprise a first end point and a second end point, the first end point being spaced inward from the edge and the second end point being adjacent the central portion,
adjacent score lines of the plurality of score lines each have respective first end points spaced apart a first distance, and the adjacent score lines each have respective second end points spaced apart a second distance, the first distance is greater than the second distance.

2. The blank of claim 1 wherein the first distance is at least approximately 25% greater than the second distance.

3. The blank of claim 1 wherein the angle is at least approximately 15 degrees.

4. The blank of claim 1 wherein the angle is at least approximately 30 degrees.

5. A blank for forming a container, the blank comprising:

a central portion;
an edge; and
a marginal portion between the edge and the central portion, the blank comprising a radius extending from a center of the blank to the edge, the marginal portion comprising a plurality of score lines, each score line being positioned to intersect the radius and being positioned at an angle relative to the radius of the blank that intersects the score line, each of the score lines comprise a first end point and a second end point, the first end point being spaced inward from the edge and the second end point being adjacent the central portion, and
the angle is at least approximately 60 degrees.

6. The blank of claim 1 wherein the score lines each have a length between the end points, the length being at least approximately 10% of the radius.

7. A blank for forming a container, the blank comprising:

a central portion;
an edge; and
a marginal portion between the edge and the central portion, the blank comprising a radius extending from a center of the blank to the edge, the marginal portion comprising a plurality of score lines, each score line being positioned to intersect the radius and being positioned at an angle relative to the radius of the blank that intersects the score line, each of the score lines comprise a first end point and a second end point the first end point being spaced inward from the edge and the second end point being adjacent the central portion,
adjacent score lines of the plurality of score lines each have respective first end points spaced apart a first distance, and the adjacent score lines each have respective second end points spaced apart a second distance,
the score lines each have a length between the end points, the length being at least approximately 30% of the radius.

8. A container formed from a blank, the blank comprising a central portion;

an edge; and
a marginal portion between the edge and the central portion, the blank comprising a radius extending from a center of the blank to the edge, the marginal portion comprising a plurality of score lines, each score line being positioned to intersect the radius and being positioned at an angle relative to the radius of the blank that intersects the score line, each of the score lines comprise a first end point and a second end point the first end point being spaced inward from the edge and the second end point being adjacent the central portion;
the container comprising:
a bottom wall formed from the central portion,
a side wall extending upwardly from the bottom wall and being formed from at least a portion of the marginal portion; and
a flange extending laterally outward from the side wall and being formed from at least a portion of the marginal portion,
the container has overlapped portions in at least a portion of the side wall and the flange, the overlapped portions being formed from the score lines in the blank and forming a first plurality of protrusions on an interior surface of the container and a second plurality of protrusions on an exterior surface of the container.

9. The container of claim 8 further comprising a stacking lug on the exterior surface extending around the side wall.

10. The container of claim 9 wherein the side wall comprises two compressed portions adjacent the stacking lug, the compressed portions each comprise a portion of the surface area of the exterior surface of the container wherein the overlapped portions are compressed.

11. The container of claim 10 wherein the stacking lugs protrude laterally outward from the compressed portions and form denesting features for separating stacked containers.

Referenced Cited
U.S. Patent Documents
1022882 April 1912 Schwenn
2522397 September 1950 Palmer
2634880 April 1953 Gravatt
3033434 May 1962 Carson
3099377 July 1963 Metzler et al.
3195770 July 1965 Robertson
3220631 November 1965 Reifers
3229886 January 1966 Grogel
3286876 November 1966 Ring
3315018 April 1967 Commeyras
3530917 September 1970 Donavan
3669305 June 1972 Kinney et al.
3680733 August 1972 Winslow
3684633 August 1972 Haase
3720365 March 1973 Unger
3850340 November 1974 Siemonsen et al.
3968921 July 13, 1976 Jewell
4051707 October 4, 1977 Valek et al.
4096947 June 27, 1978 Morse
4139115 February 13, 1979 Robinson
4183435 January 15, 1980 Thompson et al.
4202464 May 13, 1980 Mohs et al.
4606496 August 19, 1986 Marx et al.
4609140 September 2, 1986 Van Handel et al.
4704510 November 3, 1987 Matsui
4721499 January 26, 1988 Marx et al.
4721500 January 26, 1988 Van Handel et al.
4775771 October 4, 1988 Pawlowski et al.
4832676 May 23, 1989 Johns et al.
4865921 September 12, 1989 Hollenberg et al.
4890439 January 2, 1990 Smart
4935089 June 19, 1990 Schirmer
4936935 June 26, 1990 Beckett
4963424 October 16, 1990 Beckett
4967908 November 6, 1990 Kessler
5039364 August 13, 1991 Beckett et al.
5117078 May 26, 1992 Beckett
5190209 March 2, 1993 Gordon et al.
5213902 May 25, 1993 Beckett
5221419 June 22, 1993 Beckett
5260537 November 9, 1993 Beckett
5266386 November 30, 1993 Beckett
5269717 December 14, 1993 Tardif
RE34683 August 2, 1994 Maynard et al.
5340436 August 23, 1994 Beckett
5354973 October 11, 1994 Beckett
5410135 April 25, 1995 Pollart et al.
5424517 June 13, 1995 Habeger, Jr. et al.
5519195 May 21, 1996 Keefer et al.
5617972 April 8, 1997 Morano et al.
5628921 May 13, 1997 Beckett
5672407 September 30, 1997 Beckett
5758773 June 2, 1998 Clements
5759422 June 2, 1998 Schmelzer et al.
5782376 July 21, 1998 Brauner et al.
5800724 September 1, 1998 Habeger et al.
5934472 August 10, 1999 Ramirez et al.
5938112 August 17, 1999 Sandstrom
6093460 July 25, 2000 Iwaya
6114679 September 5, 2000 Lai et al.
6150646 November 21, 2000 Lai et al.
6204492 March 20, 2001 Zeng et al.
6213301 April 10, 2001 Landis et al.
6237845 May 29, 2001 Hashimoto et al.
6251451 June 26, 2001 Zeng
6325213 December 4, 2001 Landis, II
6414290 July 2, 2002 Cole et al.
6415945 July 9, 2002 Zank et al.
6433322 August 13, 2002 Zeng et al.
6455827 September 24, 2002 Zeng
6552315 April 22, 2003 Zeng et al.
6568534 May 27, 2003 Zank
6677563 January 13, 2004 Lai
6717121 April 6, 2004 Zeng et al.
6765182 July 20, 2004 Cole et al.
6988654 January 24, 2006 Wnek
20020092791 July 18, 2002 Wnek
20020113118 August 22, 2002 Littlejohn et al.
20030205319 November 6, 2003 Bengtsson et al.
20040262322 December 30, 2004 Middleton et al.
20050109653 May 26, 2005 Wnek et al.
20060198972 September 7, 2006 Ueda et al.
20070081743 April 12, 2007 Kim
20070235514 October 11, 2007 Abayhan et al.
20070253314 November 1, 2007 Jones et al.
20070267374 November 22, 2007 Middleton et al.
20090223952 September 10, 2009 Wnek et al.
Foreign Patent Documents
509 065 April 1969 DE
80 11 020 September 1980 DE
87 13 290.7 January 1988 DE
37 37 052 May 1989 DE
296 02 348 May 1996 DE
101 49 143 April 2003 DE
0 082 209 June 1983 EP
1 332 972 August 2003 EP
2 266 638 October 1975 FR
2 599 002 November 1987 FR
2 733 715 November 1996 FR
1 264 484 February 1972 GB
1 348 370 March 1974 GB
1 376 603 December 1974 GB
2 075 462 November 1981 GB
2 171 048 August 1986 GB
47-23456 October 1972 JP
54-116059 September 1979 JP
54-126887 October 1979 JP
56065866 June 1981 JP
57-8651 January 1982 JP
59-75004 April 1984 JP
03-004582 January 1991 JP
3057020 May 1991 JP
5-42928 February 1993 JP
6000843 January 1994 JP
60-96234 April 1994 JP
07-28883 January 1995 JP
08-156944 June 1996 JP
3031361 September 1996 JP
8-337234 December 1996 JP
08-337235 December 1996 JP
09-254948 September 1997 JP
2000-043840 February 2000 JP
2000-142825 May 2000 JP
2000-238760 September 2000 JP
2000-309326 November 2000 JP
2000-335550 December 2000 JP
2000-517260 December 2000 JP
2001-213420 August 2001 JP
2001-328617 November 2001 JP
2007-510598 April 2007 JP
20-0318533 June 2003 KR
WO 96-11142 April 1996 WO
WO 98-09812 March 1998 WO
WO 03/066435 August 2003 WO
WO 03/078012 September 2003 WO
WO 2004-033324 April 2004 WO
WO 2005/047126 May 2005 WO
WO 2008-049048 April 2008 WO
WO 2009/058807 May 2009 WO
WO 2009-086501 July 2009 WO
WO 2009-088904 July 2009 WO
Other references
  • EP 03 77 6279—Supplementary European Search Report.
  • PCT/US2007/081743 International Search Report & Written Opinion.
  • Notice of Reason for Rejection for JP 2012-52693 dated Oct. 10, 2013, with English translation.
Patent History
Patent number: 8777010
Type: Grant
Filed: Aug 26, 2010
Date of Patent: Jul 15, 2014
Patent Publication Number: 20110048999
Assignee: Graphic Packaging International, Inc. (Atlanta, GA)
Inventor: Patrick H. Wnek (Sherwood, WI)
Primary Examiner: Fenn Mathew
Assistant Examiner: Andrew T Kirsch
Application Number: 12/868,850
Classifications
Current U.S. Class: Structural Features For Vertical Stacking, I.e., Similar Receptacles (206/503); Nesting Or Vertical Stacking Within Container Or Within Retainer (206/499); Lamp Shades, Globes, Reflectors (206/500); Having Defined Means To Limit Extent Of Nesting (206/519); Table Dish (e.g., Plate, Bowl, Platter, Etc.) (220/574); Corrugated (220/670); Circumferentially And Axially Extending (220/673); Tray-type (229/407)
International Classification: B65D 21/00 (20060101); B65D 85/62 (20060101); A47G 19/00 (20060101); A47G 21/00 (20060101); A47G 23/00 (20060101); B65D 6/00 (20060101); B65D 8/04 (20060101); B65D 8/18 (20060101); B65D 90/02 (20060101); B65D 1/00 (20060101);